Source: SOUTH DAKOTA STATE UNIVERSITY submitted to NRP
MANUFACTURE OF DAIRY BASED INGREDIENTS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1013451
Grant No.
(N/A)
Cumulative Award Amt.
(N/A)
Proposal No.
(N/A)
Multistate No.
(N/A)
Project Start Date
Oct 1, 2017
Project End Date
Jul 31, 2020
Grant Year
(N/A)
Program Code
[(N/A)]- (N/A)
Recipient Organization
SOUTH DAKOTA STATE UNIVERSITY
PO BOX 2275A
BROOKINGS,SD 57007
Performing Department
Dairy Science
Non Technical Summary
In the U. S., milk production has steadily climbed from 115 billion lbs in 1975 to over 208 billion lbs today. This increase in milk production has been largely driven by a steady increase in milk production per cow. On average, since 1960 milk production has increased by 273 lbs per cow per year. It is interesting to note that in the last twenty years cow numbers have remained fairly constant at approximately 9.1 million. If cow numbers continue to remain constant we can expect to have an additional 2.5 billion lbs of milk (9.1 million cows x 273 lbs milk per cow) produced each year. The U.S. population grows at a rate of approximately 3 million per year. This increase in the U.S. population as well as increases in per capita consumption will partially compensate for the expected increases in milk production. However, excess milk will be available if the US dairy industry continues to maintain cow numbers. An additional potential market for the excess U.S milk supply is dairy based ingredients targeted for export markets. In fact in the last 15 years the amount of dairy products exported has more than quadrupled. This represents a drastic change from the past when the US dairy industry only exported products as a result of government export subsidies.In order to continue the trend of a rapidly expanding export market, the U.S. dairy industry needs to identify components of milk that are the most valuable and determine how these components can be economically isolated and converted intoshelf stable products that can be widely distributed and utilized as ingredients in a variety of products. The major components of milk include water (88%), lactose (4.8%), fat (3.5%), protein (3.2%) and minerals (0.70%). Of these components, protein is considered to be one of the most valuable. Currently, world demand for dairy protein exceeds the world supplyand the U.S. will have an opportunity to expand its milk production if economical systems to manufacture and fractionationmilk protein are available. In addition to protein there are also opportunities to produce dairy based ingredients that are rich in lactose, fat and minerals. The objective of this project it to develop and improve manufacturing processes to produce dairy based ingredients that have an extended shelf-life and can be utilized in domestic and international markets.The successful development or new dairy based ingredient manufacturing processes, as well as improvements in the efficiency of current dairy ingredient manufacturing processes, will allow for the continued growth of the US dairy export market. The economic impact of the US dairy export market is significant and is currently valued at 4.9 billion.
Animal Health Component
25%
Research Effort Categories
Basic
25%
Applied
25%
Developmental
50%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
5013450200050%
5013430202025%
5013470100025%
Keywords
Goals / Objectives
Project goals and objectivesThe overall goal of the project is to develop and improve manufacturing processes to produce dairy based ingredients that have an extended shelf-life and can be utilized in domestic and international markets.Objective 1: Model the drying characteristics of dairy based ingredientsto maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients.Objective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture.Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate.
Project Methods
Objective 1: Model the drying characteristics of dairy based ingredientsto maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients.The primary technique that will be utilized is called single droplet drying. Single droplet drying is performed by suspending a droplet on the tip of a glass filament and measuring the droplet diameter, mass, and temperature as the droplet is dried under controlled conditions. The data generated is then utilized to model the drying characteristics of the product in a large scale dryer. The major advantage of this technique is that it facilities small scale testing of a variety of products and eliminates the need for expensive large scale testing on a commercial scale dryer. In addition to single droplet drying, larger scale drying will also be conducted using a NIRO pilot scale dryer (20 lbs of water/hr removal) and a Dahmes two-stage commercial scale dryer (200 lbs of water/hr removal). The dairy based ingredients that will be evaluated include whey protein concetrates, micellar casein concentrates, and milk protein concentratesObjective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture.A laboratory scale crystallization set up will be developed that utilizes parallel crystallizers to conduct simultaneous experimentation on two treatments. During the crystallization process the parallel tanks will be cooled from 80°C to 18°C (rate, -0.0479°C /min) using an automatic temperature controlled water bath. Constant agitation with a variable speed agitator will be applied during the cooling cycle. The system will also accommodate seeding during crystallization. After completion of crystallization a centrifuge will be utilized to wash and decant the crystals. The mass, sizeand purity of the crystals will be determined and this data will be utilized to calculate yield and lactose crystallization efficiency.Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate.A lab scale filtration system and four pilot scale filtration systems will be utilized to conduct experiments to isolate and concentrate various components in milk, whey, permeate, and delactosed permeate. The lab scale system is an ultrafiltration plate and frame unit. The pilot scale systems include: an ultra and micro filtration single stage (two housing 3838) spiral wound format unit, a pilot scale four stage ultra and micro filtration (single housing 6438) spiral wound format unit, a nano and reverse osmosis single stage (one housing 3838 and one housing 8038) and a ceramic microfiltration uniform transmembrane pressure unit. A variety of paramters will be monitoredincluding: retentate and permeate compostion, process flux rates and fouled flux rates, in order to determine the performance of each membrane.

Progress 10/01/17 to 07/31/20

Outputs
Target Audience:The target audience for this research is the Dairy Industry. We primarily utilize the Industry Advisory Council of the Midwest Dairy Foods Research Center to facilitate transfer of the research outcomes to the dairy industry. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?This project provided the opportunity for five graduate students (Ahmed Hamman - MS student; Lee Alexander - MS student; Achyut Mishra - PhD student; Hiral Voral - PhD student; and Venkat Sunkesula - PhD student) to present their research at a national meeting. This opportunity was important for development of their presentation skills. Ahmed has gained experience in process cheese manufacture. Lee has gained experience in lactose manufacture and operation of a model crystallization system. Achyut has gained experience in experiment design of filtration trials, and compositional and functional analysis of dried dairy products. Hiral has gained experience in experimental design and single droplet drying analysis. Venkat has gained experience in operation of filtration and drying equipment and operation of a model crystallization system. How have the results been disseminated to communities of interest?The results were presented at the American Dairy Science Association and Institute of Food Technology Annual Meetings. Project summaries were also published in the Midwest Dairy Foods Research Center Annual Report which was distributed to more than 30 dairy related companies that are member of the Midwest Dairy Foods Research Center. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Objective 1: Model the drying characteristics of dairy based ingredients to maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients. (100% Accomplished) An alternative to pilot scale testing that has recently been developed is the use of a technique called single droplet drying (SDD). The SDD technique involves a single droplet suspended on the tip of a glass filament, where changes in droplet diameter, mass, and temperature are measured during drying. A predictive model generated using SDD can then be used to optimize drying conditions and dryer design. The modeling will help reduce costly plant trials and accelerate the development of new ingredients with novel functionalities. The SDD technology was utilized to evaluate the drying kinetics of WPC 80, a new ingredient called micellar casein, and infant formula. The results demonstrated that the solids content of WPC80 has a dramatic impact on the drying rate and required dryer design to facilitate efficient manufacture of WPC80. Additionally, SDD analysis showed that a new ingredient called mineral reduced micellar casein had unique drying characteristics, including modified powder morphology. This may impact re-hydration and improve its functionality when used in applications including natural and processed cheese, as well as shelf-stable dairy based beverages. Finally, SDD analysis determined the optimal drying conditions for infant formula. This analysis will be utilized to design dryers that have improved efficiency when drying infant formula. Objective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture. (100% Accomplished) In the first study, nanofiltration was used to concentrate acid whey from 5.5% solids to 22% solids. This process resulted in a >30% reduction in lactic acid and >35% reduction in ash. Lactic acid and ash, particularly the calcium (Ca), cause stickiness during spray drying thus limiting the processing and utilization of acid whey. These results indicate that it is feasible to significantly reduce the lactic acid and mineral content of acid whey using nanofiltration. In subsequent studies the nanofiltration retentate will be spray dried and the powder properties characterized. In the second study, soluble soybean polysaccharide (SSPS) was utilized as an additive to enhance lactose crystallization and improve the drying characteristics of acid whey. Acid whey obtained from Greek yogurt manufacture was vacuum concentrated and crystallized using a laboratory scale crystallization tank. During crystallization the concentrated acid whey at 70°C was fast cooled to 30°C followed by slow cooling to 18°C (rate, -0.05°C /min) under constant stirring. Both the control and treatment solutions were seeded with lactose crystals (0.027g/100g of solution) and 0.1% SSPS was added to the treatment solution. After crystallization the concentrate was spray dried using a pilot scale NIRO dryer. Acid whey powder with 0.1% SSPS addition was observed to be less sticky on the dryer surface. The findings of this study indicate that SSPS can enhance lactose crystallization in concentrated acid whey during crystallization, reduce the sticking of the powder in the dryer, and improve the drying characteristics including hygroscopicity and caking of the powder. In the third study nanofiltration was applied to eight delactased permeate samples obtained from four different manufacturers to create two separate product streams. These streams included a retentate with increased lactose concentrations on a dry basis that could be recycled in the lactose crystallization process and a permeate rich in small molecular weight minerals and organic acids (Cl, Na, K, lactic and formic acid) that has the potential to be utilized as a salt replacer. Flux rate and the composition of retentates/permeates varied between the manufacturers and was likely due to different milk compositions, cheese making practices, whey handling practices and lactose manufacturing methods. Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate. (100% Accomplished) A study was completed to develop a manufacturing process that uses a ceramic GP MF system (0.1-μm) to eliminate the need for drying to produce a highly concentrated liquid micellar casein concentrate (HC-MCC) from milk that has an extended refrigerated shelf-life. In this process skim milk was pasteurized and micro-filtered to produce 3× concentration that was subsequently diluted with water and micro-filtered to 3x concentration again. In the final step the concentrate was heated to 63°C and further concentrated (by microfiltration). The highest total solids achieved was 22%. A second study was completed to evaluate the shelf-stability and functionality of this product. The objective was to utilize highly concentrated micellar casein (HC-MC) as an ingredient in process cheese products (PCP) and examine the effect of storage (0, 30, and 60 days at 4°C) of HC-MC on functionality of process cheese products (PCP). Each PCP was cooked in a Rapid Visco Analyzer (RVA) for 4 min at 90°C, and then poured into molds and stored at 4°C for further analysis. The cooked viscosity of the PCP was not affected (P>0.05) by storage of the HC-MC and ranged from 755-769cP. This study demonstrates that HC-MC can be utilized in PCP formulations and that small but significant changes in functionality were observed when the HC-MC was stored at 4°C for 60 days. A third study was conducted to evaluate technology to increase the solids of protein concentrates prior to drying. Three replicates of MPC80 (20.07, 20.61 and 20.05% total solids) were concentrated using a nanofiltration membrane (Parker ATF 7938-LS02-ST, spacer 65 mil). Four NF treatments were used, including: NF at 22?C (NF22); NF at 50?C (NF50); HC prior to NF at 22?C (HCNF22); and HC prior to NF at 50?C (HCNF50). The average flux and final total solids were significantly (p<0.05) higher for NF conducted at 50?C compared to 22?C. HC did not have a significant (p>0.05) impact on average flux but did significantly increase (p<0.05) the final TS at 22 and 50?C. This study determined that increasing NF temperature improves nanofiltration performance and the level of total solids achieved, but also increased the SPC count of the final retentate. Subsequently the NF retentates were spray dried and functionality of the dried MPC was evaluated. There were no significant differences in solubility at 22°C or 50°C or wetting time at 22°C. However, HC significantly (p<0.05) decreased the wetting time at 50°C. This study determined that NF temperature and HC have important impacts on the functionality of dried MPC80 and can be utilized to adjust the functional characteristics of MPC80. A fourth study was completed to develop a process to produce acid curd from micellar casein that can be utilized as an ingredient in process cheese manufacture. This study demonstrated that MCC could be standardized to 3, 6, and 9% protein and acidified using lactic acid or by fermentation with culture. The acidified MCC was then warmed to 25°C, left to set for 30 minutes, cut, and finally mixed gently during heating to 45°C. Subsequently, the whey was drained from the curd. The curd can be directly utilized in process cheese manufacture or could be dried.

Publications

  • Type: Conference Papers and Presentations Status: Published Year Published: 2020 Citation: Hammam, A.R.A. and Metzger, L.E. 2020. Manufacture of imitation Mozzarella cheese without emulsifying salts using acid curd and micellar casein concentrate. Annual Meeting American Dairy Science Association. Virtual. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2020 Citation: Mishra, A. and Metzger, L.E. 2020. Effect of temperature on the performance of plate-and-frame filtration during milk protein concentrate manufacture. Annual Meeting American Dairy Science Association. Virtual. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2020 Citation: Mishra, A. and Metzger, L.E. 2020. Effect of cavitation and nanofiltration temperature on the functional properties of milk protein concentrate (MPC80). Annual Meeting American Dairy Science Association. Virtual. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2020 Citation: Hammam, A.R.A. and Metzger, L.E. 2020. Manufacture of culture-based acid curd using micellar casein concentrate. Annual Meeting American Dairy Science Association. Virtual. June 23.


Progress 10/01/18 to 09/30/19

Outputs
Target Audience:The target audience for this research is the Dairy Industry. We primarily utilize the Industry Advisory Council of the Midwest Dairy Foods Research Center to facilitate transfer of the research outcomes to the dairy industry. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?This project provided the opportunity for three graduate students (Ahmed Hamman - MS student; Achyut Mishra - PhD student; and Venkat Sunkesula - PhD student) to present their research at a national meeting. This opportunity was important for development of their presentation skills. Ahmed has gained experience in process cheese manufacture. Achyut has gained experience in experiment design of filtration trials, and compositional and functional analysis of dried dairy products. Venkat has gained experience in operation of filtration and drying equipment and operation of a model crystallization system. How have the results been disseminated to communities of interest?The results were presented at the American Dairy Science Association and Institute of Food Technology Annual Meetings. Project summaries were also published in the Midwest Dairy Foods Research Center Annual Report which was distributed to more than 30 dairy related companies that are member of the Midwest Dairy Foods Research Center. What do you plan to do during the next reporting period to accomplish the goals?Objective 1: Model the drying characteristics of dairy based ingredients to maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients. In the next year we will complete single droplet drying analysis of infant formula and continue to prepare manuscripts for submission to the journal of Dairy Science. Objective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture. A study we will completed to evaluate the impact of lactic acid and ash reduction from nanofiltration on the drying characteristics of acid whey/permeate. Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate. A process for converting micellar casein into acid casein than can be used as an ingredient in process cheese manufacture will be developed.

Impacts
What was accomplished under these goals? Objective 1:(25% Accomplished) Due to extended shelf-life, dried dairy ingredients are a major product category for global markets. During development of dairy ingredients, a number of drying trials are typically conducted to determine optimum drying conditions. The results of these trials can be critical in determining optimum dryer design. However, these trials can be expensive and time consuming. An alternative that has recently been developed is the use of a new technique called single droplet drying (SDD). The SDD technique involves a single droplet suspended on the tip of a glass filament, where changes in droplet diameter, mass, and temperature are measured during drying. This makes it possible to create a pictorial view of the drying process. Once the drying process is complete, particle morphology can be determined using microscopy, and rehydration behavior can be visually studied. A predictive model generated using SDD can then be used to optimize drying conditions and dryer design. The modeling will help reduce costly plant trials and accelerate the development of new ingredients with novel functionalities. The SDD technology was utilized to evaluate the drying kinetics of a new ingredient called micellar casein. In the SSD analysis, dry air at 90°C with a velocity of 0.8 m/s was utilized to dry a single droplet (2 ± 0.05 µL) of micellar casein. During drying the diameter change, temperature change, and mass change of the droplet were determined. The results of this analysis demonstrated that the solids content of WPC80 has a dramatic impact on the drying rate and required dryer design to facilitate efficient manufacture of WPC80. The slower drying rate at higher solids indicates that a two-stage drying process that utilizes an external fluid bed would be the ideal dryer design for drying at high solids. Additionally, the SDD analysis was utilized to determine that a new ingredient called mineral reduced micellar casein had unique drying characteristics, including modified powder morphology that may impact re-hydration and improve its functionality when used in applications including natural and process cheese, as well are shelf-stable dairy based beverages. Objective 2: (25% Accomplished) Two studies were completed to develop manufacturing processes to improve the drying characteristics of permeate produced from acid whey. In the first study, nanofiltration was utilized to concentrate acid whey from 5.5% solids to 22% solids. This process resulted in a >30% reduction in lactic acid and >35% reduction in ash. Lactic acid and ash, particularly the calcium (Ca), cause stickiness during spray drying thus limiting the processing and utilization of acid whey. These results indicate that it is feasible to significantly reduce the mineral content and lactic acid of acid whey using nanofiltration. In subsequent studies the nanofiltration retentate will be spray dried and the powder properties characterized. In the second study, soluble soybean polysaccharide was utilized as an additive to enhance lactose crystallization and improve the drying characteristics of acid whey. Acid whey obtained from Greek yogurt manufacture was vacuum concentrated to 56% total solids (30% lactose) and crystallized using a laboratory scale crystallization tank. During crystallization the concentrated acid whey at 70°C was fast cooled to 30°C followed by slow cooling to 18°C (rate, -0.05°C /min) under constant stirring. Both the control and treatment solutions were seeded with lactose crystals (0.027g/100g of solution) and 0.1% SSPS was added to the treatment solution. After crystallization the concentrate was spray dried using a pilot scale NIRO dryer. Acid whey powder with 0.1% SSPS addition was observed to be less sticky on the dryer surface. The crystallized lactose content was also significantly higher (77.46%) as compared to the control (66.56%). The findings of this study indicate that SSPS can enhance lactose crystallization in concentrated acid whey during crystallization, reduce the sticking of the powder in the dryer and improve the drying characteristics including hygroscopicity and caking of the powder. Objective 3: (40% Accomplished) A study was completed to develop a manufacturing process that uses a ceramic GP MF system (0.1-μm) to eliminate the need for drying to produce a highly concentrated liquid micellar casein concentrate (HC-MCC) from milk that has an extended refrigerated shelf-life. In this process skim milk is pasteurized and micro-filtered to produce 3× concentration that is subsequently diluted with water and micro-filtered to 3x concentration again. In the final step of the manufacturing process the concentrate is heated to 63°C and further concentrated to the highest total solids possible (approximately 22%). A second study was completed to evaluate the shelf-stability and functionality of this product. The objective was to utilize highly concentrated micellar casein (HC-MC) as an ingredient in process cheese products (PCP) and examine the effect of storage (0, 30, and 60 days at 4°C) of HC-MC on functionality of PCP. PCP formulations were prepared by mixing all ingredients in a Kitchen-aid mixer at room temperature for 30-40 min to produce a homogenous paste. A 25g sample of the mixture was weighed, tempered to 38°C, and then cooked in the rapid visco analyzer (RVA) for 4 min at 90°C. Once the PC was cooked, it was poured into molds and stored at 4°C for further analysis. The cooked viscosity of the PCP was not affected (P>0.05) by storage of the HC-MC and ranged from 755-769cP. This study demonstrates that HC-MC can be utilized in PCP formulations and small but significant changes in functionality were observed when the HC-MC was stored at 4°C for 60 days. An additional study was conducted to evaluate technology to increase the solids of protein concentrates prior to drying. Three replicates of MPC80 (20.07, 20.61 and 20.05% total solids) were concentrated using a nanofiltration membrane (Parker ATF 7938-LS02-ST, spacer 65 mil). Four NF treatments were utilized including: NF at 22?C (NF22); NF at 50?C (NF50); HC prior to NF at 22?C (HCNF22); and HC prior to NF at 50?C (HCNF50). All treatments were nanofiltered until the permeate flux dropped to less than 0.1 LMH. The average flux and final total solids were significantly (p<0.05) higher for NF conducted at 50?C compared to 22?C. HC did not have a significant (p>0.05) impact on average flux but did significantly increase (p<0.05) the final TS at 22 and 50?C. This study determined that increasing NF temperature improves nanofiltration performance and the level of total solids achieved, but also increased the SPC count of the final retentate. Subsequently the NF retentates were spray dried and functionality of the dried MPC was evaluated. The powders produced were analyzed for physicochemical and functional quality. The loose and tapped bulk density was significantly (p<0.05) higher in treatments NF at 22°C, whereas HC did not have a significant (p>0.05) impact on loose or packed bulk density. There were no significant differences in solubility at 22°C or 50°C or wetting time at 22°C; however, HC significantly (p<0.05) decreased the wetting time at 50°C. This study determined that NF temperature and HC have important impacts on the functionality of dried MPC80 and can be utilized to adjust the functional characteristics of MPC80.

Publications

  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Metzger, L. E., Vora, H. N. 2018. Single droplet drying - A new technology for optimization of drying conditions for dairy ingredients. Annual Meeting American Dairy Science Association. Knoxville, TN. June 26.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Vora, H. N., Metzger, L. E. 2018. Evaluation of drying kinetics of micellar casein concentrate and reduced-mineral micellar casein concentrate at different solids concentrations. Annual Meeting American Dairy Science Association. Knoxville, TN. June 25.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Hammam, A. A. R., Metzger, L. E. 2018. Production and storage stability of liquid micellar casein concentrate. American Dairy Science Association Annual Meeting. Knoxville, TN. June 25.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2019 Citation: Hammam, A. A. R., Beckman, S. L. and Metzger, L. E. 2019. Effect of storage on high concentrated micellar casein on the functional properties of process cheese. American Dairy Science Association Annual Meeting. Cincinnati, OH. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2019 Citation: Sunkesula, V., Hammam, A. R. A., and Metzger, L. E. 2019. Partial demineralization and deacidification of Greek yogurt acid whey by nanofiltration for improving the drying characteristics of Greek yogurt acid whey. American Dairy Science Association Annual Meeting. Cincinnati, OH. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2019 Citation: Mishra, A., and Metzger, L. E. 2019. Effect of cavitation and nanofiltration temperature on the production of MPC80. Annual Meeting American Dairy Science Association. Cincinnati, OH. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2019 Citation: Mishra, A., and Metzger, L. E. 2019. Effect of cavitation and nanofiltration temperature on the functionality of MPC80. Annual Meeting American Dairy Science Association. Cincinnati, OH. June 23.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2019 Citation: Sunkesula, V. and Metzger, L. E. 2019. Feasibility of soluble soybean polysaccharide for improving the drying ability and powder properties of Greek yogurt acid whey. Annual Meeting American Dairy Science Association. Cincinnati, OH. June 23.


Progress 10/01/17 to 09/30/18

Outputs
Target Audience:The target audience for this research is the Dairy Industry. We primarily utilize the Industry Advisory Council of the Midwest Dairy Foods Research Center to facilitate transfer of the research outcomes to the dairy industry. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?This project provided the opportunity for two graduate students (Ahmed Hamman - MS student; Hiral Voral - PhD student) to present their research at a national meeting. This opportunity was important for development of their presentation skills. Ahmed has gained experience in experiment design of filtration trials, operation of microfiltration equipment, and compositional and functional analysis of dairy products. Hiral has gained experience in operation of the single droplet drying system as well as analysis of the data obtained to model the drying characteristics of experimental ingredients How have the results been disseminated to communities of interest?The results were presented at the American Dairy Science Association and Institute of Food Technology Annual Meetings. Project summaries were also published in the Midwest Dairy Foods Research Center Annual Report which was distributed to more than 30 dairy related companies that are member of the Midwest Dairy Foods Research Center. What do you plan to do during the next reporting period to accomplish the goals?Objective 1: Model the drying characteristics of dairy based ingredients to maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients. In the next year we will complete single droplet drying analysis of micellar casein and prepare manuscripts for submission to the journal of Dairy Science. Objective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture. A study will be completed to utilize the lab scale crystallization system to develop a crystallization and drying process for acid and sweet whey permeate. Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate. The shelf-stability and functionality of highly concentrated micellar casein will be evaluated when it is utilized as an ingredient in processed cheese.

Impacts
What was accomplished under these goals? Objective 1: Model the drying characteristics of dairy based ingredients to maximize the efficiency of the drying process and accelerate the development of new dairy based ingredients. (25% Accomplished) As a result of their extended shelf-life, dried dairy ingredients are a major product category produced for global markets. During the development of dairy ingredients, a number of drying trials are typically conducted to determine optimum drying conditions. The results of these trials can be critical in determining optimum dryer design. However, these trials can be expensive and time consuming. An alternative that has recently been developed is the use of a new technique called single droplet drying (SDD). The SDD technique involves a single droplet suspended on the tip of a glass filament, where changes in droplet diameter, mass, and temperature are measured during drying. This makes it possible to create a pictorial view of the drying process. Once the drying process is complete, particle morphology can be determined using microscopy or the rehydration behavior can be visually studied. A predictive model generated using SDD can then be used to optimize the drying conditions and dryer design. The modeling will help reduce costly plant trials and accelerate the development of new ingredients with novel functionalities. The SDD technology was utilized to evaluate the drying kinetics of a new ingredient called micellar casein. In the SSD analysis, dry air at 90°C with a velocity of 0.8 m/s was utilized to dry a single droplet (2 ± 0.05 µL) of micellar casein. During drying the diameter change, temperature change, and mass change of the droplet were determined. For the diameter measurements, the change in area of the droplet was determined from a video-recording of the drying process. For the temperature measurements, data was collected by inserting a fine wire thermocouple connected to a computer via a Picometer into the center of the droplet. For the mass data, the change of displacement of a mass-measuring filament during drying was utilized to determine weight change. The data collected for diameter and mass was processed using Adobe After Effects 7.0 (Adobe Systems, USA) to enable the extraction of images. The results of this analysis have demonstrated that the solids content of WPC80 has a dramatic impact on the drying rate and required dryer design to facilitate efficient manufacture of WPC80. Additionally, the SDD analysis was utilized to determine that a new ingredient called mineral reduced micellar casein had unique drying characteristics that indicate it will have numerous potential applications including natural and process cheese as well are shelf-stable dairy based beverages. Objective 2: Develop a lab scale crystallization system and analysis protocols that will be utilized to evaluate modified manufacturing processes that improve the efficiency of lactose and permeate manufacture. (0% Accomplished) Work has not been started on this objective Objective 3: Develop and evaluate membrane based manufacturing processes that can be used to isolate or concentrate components in various dairy products including milk, whey, permeate and delactosed permeate. (20% Accomplished) A study was completed to develop a manufacturing process that uses a ceramic GP MF system (0.1-μm) to eliminate the need for drying to produce a highly concentrated liquid micellar casein concentrate (HC-MCC) from milk that has an extended refrigerated shelf-life. In this process skim milk is pasteurized and micro-filtered to produce 3× concentration that is subsequently diluted with water and micro-filtered to 3x concentration again. In the final step of the manufacturing process the concentrate is heated to 63°C and further concentrated to the highest total solids possible (approximately 22%). During this process, the MF membrane rejects the casein protein and allows passage of the whey protein. Consequently, the casein content as a percentage of total protein increases during MF. As expected, the CN as a percentage of TP increased with each subsequent stage of MF and increased from 84.8 in the original skim milk to 97.8% after the final stage of MF. In subsequent research the shelf-stability and functionality of this product will be evaluated. If the shelf-life of this product is sufficient it will eliminate the need for spray drying to extend shelf life.

Publications

  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Metzger, L. E., Vora, H. N., Annual Meeting American Dairy Science Association, "Single droplet drying-A new technology for optimization of drying conditions for dairy ingredients," Knoxville, TN. (June 26, 2018).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Vora, H. N., Metzger, L. E., Annual Meeting American Dairy Science Association, "Evaluation of drying kinetics of micellar casein concentrate and reduced-mineral micellar casein concentrate at different solids concentrations," Knoxville, TN. (June 25, 2018).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Hammam, A. A. R., Metzger, L. E., American Dairy Science Association Annual Meeting, "Production and storage stability of liquid micellar casein concentrate," Knoxville, TN. (June 25, 2018).